The Technical Transformation Plan of the Logistics Center of Hangzhou Cigarette Factory
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Project Background
Hangzhou Cigarette Factory is a modern cigarette manufacturing base of Zhejiang China Tobacco Co., Ltd. Founded in October 1949, it is one of the country’s 500 best economically profitable industrial enterprises with the largest operating scale and 36 key industrial enterprises in the national tobacco industry. one. The factory currently employs about 1,200 people. In 2011, it achieved a tax and profit of 17.82 billion yuan, making it one of the most important tax-producing enterprises in China.
Project requirements
With the continuous development of the “Eleventh Five-Year” technological transformation projects in the tobacco industry, on May 22, 2006, the State Tobacco Monopoly Administration approved the Hangzhou Cigarette Factory to implement relocation technological transformation. The first phase of the project has a total construction area of approximately 300,000 square meters. The construction area of the joint workshop where the involved logistics system is located is about 180,000 square meters, and the main body is in the shape of a “U”.
solution
Swisslog implemented a logistics system for the integrated sheet tobacco formula library, blended leaf shred library and finished tobacco library; at the same time, it is responsible for providing a total of 15 stackers for the auxiliary material balance library and the finished product turnover library.
Items include
1. The logistics system of the tobacco recipe library
According to the design of the annual output of 1.6 million large boxes in the first phase, the cigarette storehouse receives an average of about 792 cigarette packs per day, and the effective operation time for day shift storage is 8 hours. In order to minimize the frequency of forklift handling and improve the efficiency of warehousing, the operator operates the gripping truck to pick up two cigarette packets from the receiving area at a time and place them on the empty pallet of the warehousing platform. The automatic unpacking machine separates the two cigarette packs and puts them on two empty trays. The cigarette packs and the trays are sent to the cargo inspection station. After scanning the bar code, weighing, and inspecting the length, width and height of the cigarette pack tray, it is sent to the high-bay warehouse by the EMS electric monorail trolley system. The abnormal cigarette packs are sent to the manual correction platform for correction and then re-stocked. The wms warehouse management system distributes cigarette packets of the same level to different stacker lanes to ensure efficient supply of materials required for production and improve system availability.
wms receives the production tasks issued by the Zhejiang China Tobacco mEs system, and arranges the cigarette packs out of the warehouse according to the batches of cigarette packs required and according to the principle of first in, first out. The cigarette pack tray is taken out by the stacker and sent to the outbound station by the Ems trolley. The gantry robot separates the cigarette pack from the tray, and the cigarette pack is sent to a 5.3-meter steel platform by a vertical elevator. Through information tracking, barcode scanning and other error-proof design, the cigarette pack is sent to the top of the correct silk-making line, and then down to the cigarette pack buffer area on the first floor. Cigarette packs undergo barcode scanning verification and manual quality inspection, and can enter the silk making line only after they are qualified; unqualified cigarette packs will be rejected. If cigarette packs are rejected, the operator can create a quick replenishment requirement on wms, perform manual quick replenishment, or activate the cigarette pack replacement function to avoid material interruption and ensure continuous production in the factory.
Second, blending the logistics system of Yesi Warehouse
The leaf silk processed by the silk making line is transported to the packing station for packing. Each packing station has two loading positions to ensure continuous loading. The empty cigarette box of the packing station is generated from the dumping station or taken out from the elevated warehouse to ensure that it is clean and usable. After the packing is completed, the cigarette box is weighed and information interaction is carried out with the packing station, through the RFID information read and write, the cigarette box information is recorded and the cigarette box information is updated to the wms database. The cigarette box is sent to the elevated warehouse via the Ems trolley. Other shredded tobacco component bins (such as expanded shredded tobacco, stalks, thin shreds, etc.), new empty cigarette boxes or modified cigarette boxes are RFID scanned and weighed in the external receiving area and then stored in the warehouse. The storage location, identity tag, weight and other information of each cigarette box will be updated and saved in wms after it is stored in the elevated warehouse.
After receiving the production order issued by the MES system and confirmed by authorized personnel, wms releases the smoke box according to the version number, batch number of the smoke box, according to the sequence of the batch and the principle of first-in first-out. The cigarette boxes taken out from the elevated warehouse are automatically removed by the gantry box cover processing system and sent to the designated dumping platform via the Ems trolley for dumping. The cigarette box undergoes RFID information reading and interactive comparison with dumping platform information for identity confirmation. Pour the shredded tobacco in the cigarette box that meets the requirements into the dumping station; the cigarette box that does not meet the requirements will be withdrawn through the empty box conveyor line and sent to the external receiving area by the Ems trolley for manual processing. The empty smoke box after being dumped is sent to the cleaning station, which is automatically cleaned by the cleaning robot, and then manually checked for residues. The clean empty cigarette boxes are stored in the high-bay warehouse or sent to the packing station for packing.
Before switching the batch, wms transports the empty cigarette box according to the request of the dumping station, and the empty cigarette box is sent under the belt conveyor of the dumping station. The remaining shredded tobacco will be poured into the empty cigarette box. After the return of the material is completed, the operator registers the information of the smoke box in the tailings processing area and sends it to the elevated warehouse.
3. Finished tobacco warehouse logistics system
The mixed shredded tobacco mixed in the pallet is transported to the packing station and loaded into the cigarette box, and the clean empty cigarette box is transported to the cigarette box buffer area by the Ems trolley for packing. After the packing is completed, the cigarette box is weighed and the RFID cigarette box information is read and written, and the information is updated to the wms database. The cigarette boxes that have completed the information registration are sent to the high-bay warehouse by the Ems trolley. The gantry robot centrally adds and removes the cover, which simplifies the process of adding and removing the cover and improves the work efficiency.
According to the storage time of the cigarette box, wms sets the upper and lower limits of its storage time. Only smoke boxes that exceed the lower limit of storage time can be used for production. After wms receives the production order issued by the mEs system, it releases the smoke box with compound requirements. The cigarette box taken out from the high-bay warehouse is automatically removed by the gantry box cover processing system, and sent to the designated dumping platform by the Ems trolley. The cigarette box is confirmed by RFID information reading. The tobacco in the cigarette box that meets the requirements is poured into the dumping station. Smoke boxes that do not meet the requirements are sent to the rejection station for manual processing. The dumped empty smoke box is sent to the cleaning station by the Ems trolley for manual cleaning. The clean empty cigarette boxes are stored in the high-bay warehouse or sent to the packing station for packing.
Project equipment
1. Tobacco formula library
1. Separated racks for warehouse racks, 21 meters high with 5,760 pallet positions
2. 4 Vectura stackers, storage: 120 pallets/hour, out of storage: 74 pallets/hour
3. Pallet conveyor system
4. 4 pallet elevators
5. 7 Ems trolleys, about 110 meters of track, transport: 194 pallets/hour
2. Blended leaf silk library
1. Storage racks are separated into racks, 21 meters high, 5,736 smoke box positions
2. 7 Vectura stackers in storage: 237 boxes/hour, out of storage: 237 boxes/hour
3. Pallet conveyor system
4. 2 handling robots for bin cover
5. 2 bin cleaning manipulators
6. 34 Ems trolleys, about 510 meters of track, transportation: 638 boxes/hour
3. Finished Tobacco Library
1. The warehouse rack is a separated rack, 21 meters high, 4,908 smoke box positions
2. 6 Vectura stackers, storage: 151 cases/hour, out of storage: 151 cases/hour
3. Pallet conveyor system
4. 2 handling robots for bin cover
5. 19 Ems trolleys, about 465 meters of track, transport: 412 boxes/hour
In addition, it also includes: slice tobacco recipe library, blended leaf shred library and finished tobacco shred library
1. Warehousemanager warehouse manager
2. Automation-manager automation controller
3. SPOC single-point control system, auxiliary material balance warehouse and finished product turnover warehouse, a total of 15 stackers.
Three-dimensional library of tobacco recipe library
Project highlights
1. The Ems electric monorail trolley system handles long-distance and complex path transportation to ensure that the system achieves high throughput, flexibility and redundancy, while facilitating future expansion of the system;
2. Adopt smoke box storage and RFID management to promote flexible production and ensure information security;
3. Flexible emergency replenishment and tailings processing functions ensure the continuity and flexibility of production;
4. The gantry-type robot is centralized to add and remove the cover, and different needs to adopt different processing methods to simplify the process of adding and removing the cover;
The slice tobacco storehouse has designated special functions, and the leaf shred storehouse and tobacco storehouse have designated batch production, automatic batch addition and flexible downgrade functions;
5. Adopt international leading control technology, network technology and data interface to ensure system safety and provide convenience for future expansion and upgrade.
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